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A method and apparatus for molding a plate having highly detailed surface features from a thermosetting resin with a high concentration of a filler such as graphite. The method an apparatus provides for the formation of a preform of casting material and the placement of the material in a cavity mold

A method and apparatus for molding a plate having highly detailed surface features from a thermosetting resin with a high concentration of a filler such as graphite. The method an apparatus provides for the formation of a preform of casting material and the placement of the material in a cavity mold which is precisely temperature controlled, has vacuum assist operating throughout the molding operation. The molding pressure is rapidly increased to flow the material through the molding cavity prior to the onset of curing and uniquely positioned ejector pins are provided for removal of the molded plate without damage to the detailed surface features.

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1. A mold assembly comprising:a first platen and mold cavity portion; a second platen and mold cavity portion, the first and second mold cavity portions constructed and arranged for receiving in a mold cavity thereof; a preform billet comprising a thermosetting resin and at least about 50% by weight

1. A mold assembly comprising:a first platen and mold cavity portion; a second platen and mold cavity portion, the first and second mold cavity portions constructed and arranged for receiving in a mold cavity thereof; a preform billet comprising a thermosetting resin and at least about 50% by weight of a graphite filler material, the preform billet having a cross-sectional area in the plane of the mold cavity portions which is only a fraction of the area of the mold cavity portions; a press for performing a molding operation, wherein the press is capable of forcing the first and second platen and mold cavity portions together in an interfitting relationship, thereby compressing and flowing the preform billet into a molded plate with features therein defined by the first and second cavity portions; and wherein the molded plate includes at least one diaphragm area having a thinner web of molded material therein which is readily removable from the molded plate when it is put in use. 2. The mold assembly of claim 1 wherein the first and second platens each also comprise a plurality of heating elements embedded therein, the heating elements constructed and arranged for maintaining a selected elevated temperature of the first and second cavity portions during the molding operation.3. The mold assembly of claim 2 wherein temperature sensors are embedded in the first and second platens adjacent to at least one of the of the heating elements for providing a measurement of the platen temperature to temperature control circuitry driving heating elements adjacent to the temperature sensors.4. The mold assembly of claim 3 wherein each temperature sensor is positioned adjacent at least one heating element and temperature control circuitry associated with it controls the temperature of those heating elements.5. The mold assembly of claim 3 wherein the selected elevated temperature lies in a range between about 270 and 320 degrees Fahrenheit.6. The mold assembly of claim 5 wherein the selected elevated temperature is maintained to within 5 to 10 degrees Fahrenheit across the molded part throughout the molding operation.7. The mold assembly of claim 1 wherein the press opens the mold cavity by separating the mold cavity portions and at least one of the first and second cavity portions also comprises ejection devices positioned at various locations across the surface of the molded part, the ejection devices constructed and arranged for actuation during the opening of the cavity defined by the first and second cavity portions.8. The mold assembly of claim 7 wherein both of the first and second cavity portions comprise ejection devices.9. The mold assembly of claim 7 wherein the ejection devices comprise a plurality of ejector pins mounted on a separate ejector plate for movement relative to a cavity portion during actuation to apply an ejection force to the molded part as the mold cavity opens.10. The mold assembly of claim 1 wherein both of the first and second cavity portions also comprise ejection devices at various locations across the surface of the diaphragm areas of the molded plate, the ejection devices constructed and arranged for actuation during the opening of the mold cavity.11. The mold assembly of claim 10 wherein the first and second platen and mold cavity portions also comprise interfitting vacuum seals and the press also includes vacuum manifolds communicating to the mold cavity for establishing a partial vacuum between the first and second mold cavities during the molding operation.12. The mold assembly of claim 11 wherein the partial vacuum is established in the mold cavity before the mold cavity portions are fully closed.13. The mold assembly of claim 1 wherein the first and second cavity portions are formed from tool steel coated with a polyfluorotetraethylene material.14. The mold assembly of claim 1 wherein outside edges of the first and second cavity portions when the mold cavity is fully closed are constructed and arranged for providing a parting line gap of about approximately 0.007 inches remains open around the perimeter of the part upon completion of the molding operation.15. The mold assembly of claim 14 wherein the first and second cavity portions have a projecting land portion around substantially their entire circumference at the parting line, the land potions each being parallel to each other and the face of the molded part and separated from each other by about approximately 0.007 inches when the first and second cavity portions are in a closed position.16. The mold assembly of claim 1 wherein the press is capable of applying a molding pressure of at least about 300 tons within about 0.5 to 3 seconds as the molding operation is performed.17. A mold assembly comprising:a first platen and mold cavity portion; a second platen and mold cavity portion, the first and second mold cavity portions constructed and arranged for receiving in a mold cavity thereof; a preform billet comprising a thermosetting resin and at least about 50% by weight of a graphite filler material, the billet having a limited cross-sectional area in the plane of a surfaces of the mold cavity portions relative to the area of the surfaces of the mold cavity portions; the first and second mold cavity portions constructed and arranged for performing a molding operation, wherein the press is capable of forcing the first and second platen and mold cavity portions together in an interfitting relationship and compressing the preform billet into a molded part with features therein defined by the first and second cavity portions. 18. The mold assembly of claim 17 wherein the first and second platens each also comprise a plurality of heating elements-embedded therein constructed and arranged for maintaining a selected elevated temperature of the first and second cavity portions during the molding operation.19. The mold assembly of claim 18 wherein the selected elevated temperature lies in a range between about 270 and 320 degrees Fahrenheit.20. The mold assembly of claim 17 wherein the selected elevated temperature is maintained to within 5 to 10 degrees Fahrenheit across the molded part throughout the molding operation.21. The mold assembly of claim 17 wherein the mold cavity portions are separable to open the mold and at least one of the first and second cavity portions also comprises ejection devices positioned at various locations across the surface of the molded part, the ejection devices constructed and arranged for actuation during the opening of the cavity defined by the first and second cavity portions.22. The mold assembly of claim 21 wherein both of the first and second cavity portions comprise ejection devices.23. The mold assembly of claim 21 wherein the ejection devices comprise a plurality of ejector pins mounted on a separate ejector plate for movement relative to a cavity portion during actuation to apply an ejection force to the molded part as the mold cavity opens.24. The mold assembly of claim 17 wherein the molded part includes at least one diaphragm area having a thinner web of molded material therein which is readily removable from the molded part when it is put in use and wherein both of the first and second cavity portions also comprise ejection devices at various locations across the surface of the diaphragm areas of the molded part, the ejection devices constructed and arranged for actuation during the opening of the mold cavity.25. The mold assembly of claim 17 wherein vacuum providing means are provided for establishing a partial vacuum between the first and second mold cavities during the molding operation.26. The mold assembly of claim 17 wherein the first and second cavity portions are formed from tool steel coated with a polyfluorotetraethylene material.27. The mold assembly of claim 17 wherein outside edges of the first and second cavity portions when the mold cavity is fully closed are constructed and arranged for providing a parting line gap of about approximately 0.007 inches remains open around the perimeter of the part upon completion of the molding operation.28. The mold assembly of claim 27 wherein the first and second cavity portions have a projecting land portion around substantially their entire circumference at the parting line, the land potions each being parallel to each other and the face of the molded part and separated from each other by about approximately 0.007 inches when the first and second cavity portions are in a closed position.29. The mold assembly of claim 1 wherein the preform billet is generally cylindrical with its axis substantially perpendicular to the surface of the at least one of the first and second mold cavity portions.30. The mold assembly of claim 29 wherein the preform billet has a diameter of about approximately 3 inches.31. The mold assembly of claim 30 wherein the molded plate is about approximately 10 inches by 12 inches.32. The mold assembly of claim 17 wherein the shape of the preform billet is generally cylindrical with its axis substantially perpendicular to the surface of the at least one of the first and second mold cavity portions.33. The mold assembly of claim 32 wherein the preform billet has a diameter of about approximately 3 inches.